Artificial grass mat



' P 1935. M. E. GOTTLlE-B ARTIFICIAL GRASS MAT Filed Aug. 13, 1934 INVENTOR. MAX 5 60772/58 ATTORNEY.

Patented Sept. 3, 1935 UNITED STATES PATENT OFFICE ARTIFICIAL GRASS MAT Max E. Gottlieb', Cleveland Heights, Ohio Application August 13,1934, Serial No. 739,629 ifllaims. (oi. 2-.-27s) This invention relates to artificial covering materials used for decorative purposes or for concealing discordant or offensive objects from view. More particularly this invention relates to mats 5 made artificially to simulate grass such as employed by window dressers to enhance their displays, and by stage decorators to represent grass plots, and by golf schoolsv as indoor putting greens, and by funeral directors and cemeteries attendants to conceal the freshly excavated earth around the grave and to make the grave appear less offensive to mourners.

Artificial mats simulating grass have been made and used for .a long time. These mats usually consist of a flexible woven fabric backing m'ember to which rows of short fibers are secured, usually by stitching, the-rows being spaced from each other. The usual material used for the fibers consists of rafiia or similar material. The fibers in these rowsare brushed after attachment to the backing until they assume a position resembling grasaand are then dyed tosimulate the color of grass, after which theyare fireproofed and otherwise treated to improve'their appearance and to resist the elements and wear and tear. All of the artificial grass matsof this type in commercial use, so far as I am aware, have the rows of short fibers stitched to the backing by means of a single line of stitching running along the center of the row and have both ends of the short fibers projecting upwardly from the backing after brushing. these rows are applied to a backing sheet, the rows in one layer running crosswise relatively to the rows in the other layer.

All the mats made-as described above havethe "disadvantage that when the mat is bent about a relatively sharp corner, the backing, usually a coarse fabric, becomesexposed to view. This exposure of the backing fabric destroys the illusion which is intended to be effected. This difliculty is accentuated by the fact that the backing material usually takes-the dye differently than the grass simulating fibers and has a difierent type of surface than that of the fibers thus re-- fleeting the light difierently and making the ex posed backing portion correspondingly more conspicuous. All of the fibers on the above described construction are secured to the backing by means of a single stitch only and the detaching of fibers in normal use is therefore considerable, due to the insufliciency ofthis single stitch line type of fastening. It will also be noted that the back- ,ing, being necessarily relatively flexible easily Sometimes two layers of description and claims.

their original straight position and tend to return to theoriginal fiat condition thus exposing m the central seam portion of the row. All of the defects pointed out above become more pronounced with the increase in age of the mat.

It is therefore, one of the objects of this invention to produce a mat of the class described 15 which will at no time and under no circumstances expose any of the backing material and in which, when the mat is bent, no material is exposed to View except the grass simulating fibers.

' A further object ofthis invention is to produce 59 a grass resembling mat in which the separate fibers will be more securely fastened to the backing member in order that they may not be detached from the backing member in normal use.

A further object of this invention is to pro- 25 duce a mat; in which the fibers will better maintain their brushed upwardlyprojecting position with relation to the backing.

A further object of this invention is to produce a mat which will have a substantial body throughout its entire area and which will not bend to form a sharp corner in use. I

A further object of this invention is to produce a mat of this type which will present a relatively smooth and: uniformly resilient upper surface which will well adapt the mat for such uses as artificial putting greens for golf practice.

A further object ofthis invention is to provide a mat of this type which-will be improved in appearance, economical'to manufacture, and durable in use. 7

Further and more specific objects of this invention will become apparent from the following This description sets forth in detail a certainconstruction embodying this invention, such disclosed construction constituting however, but one of the forms in which the principle of this invention may be applied.

Referring to the, annexed drawing:

Fig. 1 is a plan view of my'improvedmat, this view showing the mat to a reduced scale, in a partially completed condition, that is, in a condition in which only a part of the rows of material which are to be applied to a backing sheet are shown and in which that material is shown only in a partly finished state.

Fig. 2 is an enlarged detached view of a few such as illustrated in Fig. 2, applied to the backing sheet.

Fig. 4 is a view similar to Fig. 3 but showing the mat in a slightly further advanced state after the second row of fibrous material has been added to the backing sheet.

Fig. 5 is an enlarged view similar to Fig. 4 showing the mat in a still further advanced state of completion with several additional rows of fibrous material added to the backing sheet, this view actually representing a transverse section thru the partly completed mat illustrated in Fig. 1 as it appears on the plane indicated by line 5, 5 in that figure.

Fig. 6 is a plan view of my improved mat, illus trated to the same scale as Fig. 1 but showing the mat as it appears after completion.

Fig. 7 is an enlarged transverse section of the completed mat taken on the plane indicated by line 1, 1 in Figure 6 and showing the same portion of the mat as is represented by Fig. 5 after certain finishing operations have been performed.

Fig. 8 and Fig. 9 are views similar to Fig. 7 showing modified forms of this invention.

Referring to the form of my invention shown.

in Figures 1 to 7 of the drawing, the backing sheet which comprises the supporting member upon which my improved artificial grass is formed, is indicated at "I. This backing sheet maybe made of any suitable flexible material whichmay be woven, felted or produced in any other manner. I prefer to use a firm burlap because of the substantial body and good wearing qualities of this material and because of its open nature which permits ventilation and prevents deterioration of the artificial mat when in storage.

I then out long threads or fibers of suitable ma- .terial into uniform short lengths. A few of these short lengths of fibers, in loose form, are shown.

parallel to each otherto form a row across the backing sheet and are then secured to the burlap by meansof a stitch line. The first row of these fibers is preferably applied adjacent the edge of the sheet as shown in Fig. 3 to form a row l2, secured by a stitch line l3. In this manner a row or ribbon of fibers is formed and secured to the backing .member, the individual fibers running transversely of the length of the row. The stitch line 13 is located at a predetermined desired point intermediate the ends of the fibers. The fibers in the row I! are thus each divided into two portions by the stitch line, a right portion, as viewed in Fig. 3, shown at I4, and a left portion as shown at I I. 1 It will be noted in the construction shown in Fig. 3, that the stitch line l3 runs substantially thru the center of the fibers and that the portions I4 and I5 are substantially of the same length.

After the first row l2 has been attached to the backing ID as indicated in Fig. 3, additional short fibers II are assembled in a row and superimposed upon the portion ii of the first row l2 as shown in Fig.4, to form a second row I2a. As shown, the central portion of the row lZa is superimposed upon the portion I5 adjacent the outer end of the fibers but at a point located a substantial distance from the outer end of the fiber portion 15. A stitch line l3a is-then run thru the center of row 12a and thru the end of the portion l5 of the fibers of row I2 and thru the burlap "I, as clearly shown in Fig. 3.

After the row 12a, has been applied for the full distance across the burlap, additional rows of fibers are successively superimposed upon the portions l5 of the previously applied rows, placing the centers of the superimposed rows upon the ends of the portions I5 but always carefully spaced from the ends of the fiber portions l5 thus insuringthe passage of the stitch line thru the 7 end portionsl5 of the previously applied rows.

Several additional rows and stitch lines thus added are indicated at l2b, I20, l2d, and Nb, I30, and I Sirespectively, in Figures 1 and 5. It will be evident that the distance between the adjacent stitch lines is less than the length of the portion |5 which is firmly secured to the backing by the stitch lines. It will also be apparent that the portions I4 of all of the several rows of fibers are free to-project upwardly from the backing.

. After the entire backing sheet ID has been completely covered with rows of fibers in the manner above set forth this mat is completed substantially aafollows:

The portionjll of the fibers is brushed in all directions by any desired means to cause these fibers to project vertically in different directions relative to the surface of the backing in order to cause these fibers to simulate the position assumed by natural grass blades. After brushing, the mat is then dyed a suitable color, such as grass green, in the event that the mat is intended to simulate grass. This dyeing is done with high pressuresteam and the dye completely penetrates the fiber. Thereafter the mat is subjected to a further brushing and the fibers are preferably treated with glycerine to produce a natural velvety luster. The fibers are then chemically treated to prevent rotting and are fireproofed with calcium chloride which treatment additionally causes moisture to be attracted to the fibers thus producing a moist sensation when the fibers are touched. The steps outlined above may be modified or amplified to suit the judgment of the operator and to suit the varying requirements which have to be satisfied.

The completed mat is shown to a reduced scale in plan in Fig. 6 and in an enlarged fragmentary vertical section in Fig. 7, where the brushed fibers are indicated at Ma.

It will be evident that two stitch lines run thru the portion 15 of the fibers in all of the rows and that all of these fibers, being secured to the backing at two places, will be firmly anchored to the backing and that the likelihood of their becoming detached in service is thereby reduced to a minimum.

It should also be noted thatin the brushing operation, the portions ii of the fibers which are all attached to the backing by two stitch lines as stated and by the method specifically shown in Figures 3, 4, and 5, is not brushed nor disturbed in any manner. This portion liremains firmly secured to the backing and substantially parallelto the backing at all times, as clearly shown in'the section thru the finished mat in Fig. 7,.

It will be apparent that the. backing sheet of the artificial grass mat produced as stated is provided with a' complete and permanent covering of fibrous material l5 whichconceals the backing sheet from the face of the mat under all circumstances, andthat it is not possible to determine from the face of the material what the nature of the backing is, unless the portion l5 of the fiber rows is purposely and willfully distorted or destroyed.

It .will also be apparent that the number of fibers forming the portion I5 attached to the burlap by double stitching, is the same as the number of fibers in the portion l4 forming the upwardly projecting fibers of the grass mat. Due to the fact that a very substantial number of fibers are required in the upwardly projecting portion M to produce a satisfactory appearing grass mat a sufiiciently satisfactory covering l5 isalso assured to effectively concealthe backing.

It will further be evident that the combined body or substance of the backing l and the fibrous covering I is quite heavy and substantial and will not become flabby, nor will it bend sharply about square corners, to destroy the illusion of natural grass.

It will also be apparent that all 01' the rows of fibers are parallel to each other and that the fibers in turn are all parallel to one another and all extend in a direction transverse tov the parallel spaced stitch lines when applied to the backing.

It will immediately be apparent that this construction, while requiring slightly more material to produce an equal number of upstanding grass blade resembling fibers, requires less labor to produce than other types of construction in which two layers of material are applied and in which the rows in different layers run in different directions, and which therefore require much more handling than the herein disclosed construction.

It will also be evident that if any of the upwardly projectingflbers ll become worn or dctached due to unusual wear, that the portion I5 01! the fiberswill come 'into view and, at a slight,

distance, it will be impossible to detect the absence of even a considerable number oi upwardly projecting fibers-due to the fact that the color and the reflective index 01 the fibers Ii, firmly fixed to the mat, are identical with the color and reflective' index of the upwardly projecting fibers.

' It will also be evident that the original and natural positions of the fibersare straight and that the fibers naturally tend to return to the straight position. In other mats with which I am familiar, and in which both the portions l4 and are brushed upwardly from .thebacking sheet, the fibers are bent substantially about an angle of 180", in the rows. The tendency urging these fibers to return to their original straight position is naturally in proportion to the amount of their deflection from their original straight position, thus tending to expose the central stitch lines and the adjacent regular and parallel appearance of fiber portions. Y a

In the artificial ass produced by my improved method the fibers are deflected an amount averaging only 90 from the original position, as will appear from Fig. 7, and consequently will have only one halt the tendencyto return to the flat position as compared with those fibers in other artificial mats which are bent 180,thus insuring a lowered tendency to expose the seam lines.

It will also be clear that the grass resembling fibers will still remain attached to the backing even tho some of the stitches are broken or torn, for they reason that if one row of stitches does not hold the fibers, the other row will. 1

This invention naturally lends itself to several modified constructions; for instance, I have shown in Fig. 8 a construction in which the portions of the rows 22, 22a, and 22b each secured by a double row of stitch lines 23, 23a, and 23b as shown, is longer than the upwardly projecting portion of the fibers 2411. This modified construction may be used to advantage when less intense distribution of upwardly projecting fibers is required. 1

Fig. 9 shows another modification in which the portions of the rows 32, 32a, and 32b each secured by double stitch lines 33, 33a, and 33b, are shorter than the upwardly projecting portions 340. of the fibers. This construction may advantageously be used when longer fibers or a more dense distribution of the upstanding fibers is required.

While I have described the process of forming the rows by stating that the individual short fibers are laid upon the burlap and then stitched to the burlap to form rows, I may also produce the rows preformed rows to the burlap.

It willalso be understood that the rows need not be placed parallel to one of the edges of the backing sheet. The rows might equally well be placed diagonally on the backing material thus making it more difiicult for the eye to follow the original row arrangement of the mat.

While this invention has been described largely as applied to the production of an artificial grass mat, it will be understood that many other similar artificial materials might advantageously backing sheet and a series of rowscomposed of individual superimposed ratfia fibers, each of said fibers being secured to the backing sheet sub- 5 stantially at the center of the fiber and at one end of the fiber, by suitably spaced stitch lines, and projecting upwardly ,from the sheet at its other end, whereby the upper surface of the backing sheet between said spaced stitch lines is concealed by a layer'of superimposed rama fibers 2. An artificial grass mat including a flexible.

backing sheet and a series of rows of grass simulating fibers secured to the backing sheet by stitch lines, each row consisting of a plurality of separate fibers superimposed upon each other, each of said fibers being secured to the backing sheet by two stitch lines, one of said stitch lines gripping the fibers substantially at the center line of the 'row and the other stitch line grippingthe separate ends of said fibers at one side of said row and the fibers of the next adjacent row substantially at the center line thereof, the free ends of the fibers projecting outwardly from separately from the burlap and then stitch the 3 substantially through the central portion of the fibers, said rows being parallel to each other and the central portion of each row being superimposed upon and secured by said stitch line to the backing over and through the edge portion of a next adjacent row, whereby the said edge portion is stitched to the backing material and whereby a substantial portion of the fiber is free to project outwardly from the backing sheet, the spacing between said stitch lines being approximately equal to one half the length of the individual fibers.

4. An artificial grass mat including a flexible backing sheet, a row comprised of a multiplicity of individual relatively short superimposed raifia fibers of approximately equal length secured to the backing sheet by a stitch line passing substantially through the center of the fibers, a second row of similar individual superimposed rafiia fibers laid upon the first row parallel to but offset therefrom to an extent slightly less than one half of the length of the fibers whereby the approximate central portion of the fibers in the second row contacts the ends of the fibers in the first row, and a stitch line passing substantially through the center of the fibers in the second row and through the separate ends of the fibers of the first row whereby the portion of the fibers secured between said stitch lines is substantially parallel to the backing sheet, the unsecured portion of each of the fibers in each row projecting outwardly in disordered directions relatively to the backing sheet.

MAX E, GO'ITLIEB. 

